Method and device for producing a profiled element

ABSTRACT

A profile element is useful for sealing building-structure joints, especially for sealing against sound and smoke and optionally against fire. An apparatus is useful for manufacturing such profile element and to the use of the profile element manufactured according to the invention for the acoustic, smokeproof and/or fireproof sealing of connecting joints in drywalls, especially of expansion joints.

FIELD OF THE INVENTION

The present invention relates to a method for manufacturing a profileelement for sealing building-structure joints, especially for sealingagainst sound and smoke and optionally against fire, to an apparatus formanufacturing such a profile element and to the use of the profileelement manufactured according to the invention for the acoustic,smokeproof and/or fireproof sealing of connecting joints in drywalls,especially of expansion joints. In particular, the invention relates toan improved method for continuous and endless manufacture of such aprofile element.

BACKGROUND OF THE INVENTION

Connecting joints are usually formed when different building parts meet.Connecting joints are found in the region of connection to theinter-story ceiling, to the floor and to massive walls. Due to weightloading or thermal influences, the ceiling in buildings may be forcedupward or downward. To prevent damage to the drywall, the upperconnecting joint in this case is made as an expansion joint. Thus jointsfor creating discontinuities in building parts in order to preventstress cracking are known as expansion joints. The ceiling profile ismade in such a way that a relative movement between ceiling profile andthe vertical wall components is possible.

In general, a channel profile constituting part of the studwork isfastened to the connecting building parts. The gypsum boards themselvesare attached at a well-defined spacing to the connecting building part.Usually sealing of the system is provided in the gap between gypsumboard and ceiling. For this purpose, either a suitable sealing compoundis introduced, processed with joint spray, or else the gap is providedwith a joint cord or filled with mineral wool and provided at thesurface with a sealing layer. In these cases, the material present inthe joint presents relatively strong resistance to movement, with theconsequence that comparatively large joint widths are necessary in orderto achieve adequate movement absorption.

Different methods for manufacturing profile elements, such as profilestrands and joint cords, for sealing of building-structure joints,especially connecting joints, against smoke and fire are known from theprior art.

DE 3038524 A1 describes an expansion-joint tape, which is provided witha flexible tube, wherein the expansion-joint tape is introduced into ajoint between the concrete elements. The flexible tube is used to fillsubsequently with further joint material, such as polyurethane, in orderto seal the joint at a later time, but this makes mounting and handlingdifficult.

DE 4006997 A1 describes a method and an apparatus for manufacturingprofile strands of fire-protection foam materials using a reactionmixture that is prepared in a mixer then filled into a closed, flexibleand airtight film tube, wherein the film tube is removed before use ofthe profile strand.

DE 102010008570 A1 describes a method for manufacturing afire-protection joint cord, wherein an intumescent foam flows into atube and is foamed. A disadvantage in DE 102010008570 A1 is thepredetermined diameter of the tube as well as backing-up of the materialcompound that may occur during the manufacturing process or isinsufficient material compound in the manufactured joint cord.

The prior art systems exhibit further additional disadvantages, such as,for example, considerable time consumption during manufacture due tocomplex steps of cleaning of the system or due to tedious setting-up,high costs, buildup of the joint cord or of the profile elementcomprising several components or complex construction elements, poorcuttability, high weight or very inconvenient mounting forbuilding-structure joints, especially for connecting joints.

The object of the invention is therefore to provide a method formanufacturing a profile element for sealing building-structure joints,especially for sealing against sound and smoke and optionally againstfire, which method avoids the disadvantages of the known methods. Inparticular, the object of the present invention is to provide animproved method for continuous and endless manufacture of such a profileelement.

A further object of the present invention is to provide an apparatusthat permits cost-effective, economic, continuous and endlessmanufacture of a profile element.

A further object of the present invention is to provide the use of theprofile element manufactured according to the invention for acoustic,smokeproof and/or fireproof sealing of connecting joints in drywalls,especially of expansion joints.

These and further objects that will become apparent from the descriptionof the invention hereinafter are solved by the present invention, asdescribed in the independent claims. The dependent claims relate topreferred embodiments.

SUMMARY OF THE INVENTION

The present invention relates to a method for manufacturing a profileelement for sealing a building-structure joint, comprising the followingsteps:

a) providing a film,

b) applying a free-flowing reaction mixture on an upper side of thefilm,

c) joining a first side-edge region of the film with a second side-edgeregion of the film to create a substantially cylindrical profileelement, wherein the volume of the free-flowing reaction mixture to beapplied is dosed such that it corresponds to the inside volume of themanufactured profile element, and wherein the film completely enclosesthe reaction mixture.

The present invention further relates to an apparatus for manufacturinga profile element for sealing a building-structure joint, with a castingsystem for mixing and applying a free-flowing reaction mixture,characterized by

a) a feed apparatus for feeding the film,

b) a roll for perforating the film,

c) at least one conveying means for laying the film flat and conveyingit,

d) a forming shoulder for shaping the profile element,

e) a thermal welding system for joining a first side-edge region of thefilm with a second side-edge region of the film,

f) a reaction section for foaming the free-flowing reaction mixture,

g) conveying equipment for exactly guiding the film,

h) a cutting unit for cutting the profile element to the desired length,and

i) optionally at least one metal profile for shaping the profile to thedesired geometry.

The present invention further relates to the use of the profile elementmanufactured according to the invention for acoustic, smokeproof and/orfireproof sealing of connecting joints in drywalls, especially ofexpansion joints.

Some other objects and features of this invention are obvious and somewill be explained hereinafter. In particular, the subject matter of thepresent invention will be described in detail by reference to thefollowing figures:

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a sketched embodiment of the inventive apparatus formanufacturing a profile element.

FIG. 2a shows a sketched front view of an embodiment of a profileelement manufactured according to the invention.

FIG. 2b shows a cross section through an embodiment of a profile elementmanufactured according to the invention.

FIG. 2 shows a perspective view of an embodiment of a profile elementmanufactured according to the invention.

FIG. 3 shows the application of an embodiment of a profile elementmanufactured according to the invention for acoustic, smokeproof and/orfireproof sealing of connecting joints in drywalls.

DETAILED DESCRIPTION OF THE INVENTION

The following terms are used within the scope of the present invention:

Within the scope of the present invention, the term “profile geometry”comprises various cross-section types of the profile element. This meansthat particularly the sealing regions of the profile element may havedifferent cross-section types. Cross-section types are understood amongother possibilities as round profile (round cross section), polygonalprofile (polygonal cross section), especially square profile (squarecross section), rectangular profile (rectangular cross section),parallelogram profile (cross section in the shape of a parallelogram),triangular profile (triangular cross section), etc.

Within the scope of the present invention, the term “deformable” meansthat irregularities in the building part, against which the profileelement is pressed, can be evened out. In this connection, “plasticallydeformable” means that the profile element is deformable and no longerreturns to its original shape after deformation. Analogously,“elastically deformable” means that the profile element is deformableand returns to its original shape after deformation, i.e. the materialcan be deformed reversibly to a certain extent.

The terms “exhibit”, “with” and “have” are intended to be inclusive andmean that elements other than those cited may also be meant.

Within the scope of the present invention, the term “intumescence” meansthat, under the effect of heat, for example in the event of a fire, thematerial swells and forms an insulating layer of flame-retardantmaterial, i.e. intumescence.

Within the scope of the present invention, “slow-burning foam” isunderstood as a foam that offers no possibility of fire propagation dueto the foam, is not spontaneously flammable and also does not drip.

As used within the scope of the present invention, the singular forms“one”, “a” and “an” also include the corresponding plural forms, unlesssomething different can be inferred unambiguously from the relationship.Thus, for example, the term “one” is intended to mean “one or more” or“at least one”, unless otherwise indicated.

In one aspect, the present invention relates to a method formanufacturing a profile element for sealing a building-structure joint,comprising the following steps:

a) providing a film,

b) applying a free-flowing reaction mixture on an upper side of thefilm,

c) joining a first side-edge region of the film with a second side-edgeregion of the film to create a substantially cylindrical profileelement, wherein the volume of the free-flowing reaction mixture to beapplied is dosed such that it corresponds to the inside volume of themanufactured profile element, and wherein the film completely enclosesthe reaction mixture.

In a further aspect, the present invention relates to an apparatus formanufacturing a profile element for sealing a building-structure joint,with a casting system for mixing and applying a free-flowing reactionmixture, characterized by

a) a feed apparatus for feeding the film,

b) a roll for perforating the film,

c) at least one conveying means for laying the film flat and conveyingit,

d) a forming shoulder for shaping the profile element,

e) a thermal welding system for joining a first side-edge region of thefilm with a second side-edge region of the film,

f) a reaction section for foaming the free-flowing reaction mixture,

g) conveying equipment for exactly guiding the film,

h) a cutting unit for cutting the profile element to the desired length,and

i) optionally at least one metal profile for shaping the profile to thedesired geometry.

In yet a further aspect, the present invention relates to the use of theprofile element manufactured according to the invention for acoustic,smokeproof and/or fireproof sealing of connecting joints in drywalls,especially of expansion joints.

It has been discovered that the inventive method is particularlysuitable for manufacturing a profile element in simple, continuous,economic and cost-effective manner, for safely sealing abuilding-structure joint between two adjacent building parts, especiallyagainst sound and/or smoke and optionally also against fire.

Therefore it is an objective of the present invention to describe themethod for manufacturing a profile element for sealing abuilding-structure joint. Furthermore, it is an objective of the presentinvention to describe in detail the apparatus for manufacturing aprofile element for sealing a building-structure joint. Furthermore, itis an objective of the present invention to describe the use of theprofile element manufactured according to the invention for acoustic,smokeproof and/or fireproof sealing of connecting joints in drywalls,especially of expansion joints.

Such a profile element can be manufactured according to the invention byapplying a suitable free-flowing reaction mixture on a flat film, thenjoining a first side-edge region thereof with a second side-edge regionto create a substantially cylindrical profile element, wherein thefoaming, deformable material then passes together with the film througha reaction section and is formed to a profile element.

Therefore the inventive method for manufacturing a profile element forsealing a building-structure joint comprises the following steps:

a) providing a film,

b) applying a free-flowing reaction mixture on an upper side of thefilm,

c) joining a first side-edge region of the film with a second side-edgeregion of the film to create a substantially cylindrical profileelement, wherein

the volume of the free-flowing reaction mixture to be applied is dosedsuch that, in the fully reacted state, it corresponds to the insidevolume of the manufactured profile element, and wherein the filmcompletely encloses the reaction mixture.

Furthermore, the inventive method comprises the following steps:

d) foaming the free-flowing reaction mixture,

e) optionally shaping the profile to the desired geometry, and

f) cutting the profile element to the desired length.

According to the invention, what takes place in the first step of themethod is the provision of a film by means of a feed apparatus, whichcomprises at least one roll, over which the film is fed from a filmsupply to a rotating roll for perforation.

Expediently, the provided films consist of plastic. The material of thefilm is preferably a plastic material, which does not form any adhesivebonds with the foam system and withstands the foaming pressures withoutadditional bracing mold. Alternatively, if other films are used, forexample of paper or fabric, the foaming in the film sheath may also takeplace in a bracing mold, which defines the outer contour of the film asit expands during the foaming process.

In the inventive method, the film is preferably provided as a perforatedfilm. Suitable film materials, among others, are polymers, such as, forexample, silicone, polyethylene, polypropylene, polyurethane, polyvinylchloride, rubber and/or mixtures thereof. Preferably the film isprovided as a polyethylene film. In a particularly preferred embodimentof the film, the film is a perforated polyethylene film.

Perforation of the film can be achieved by means of a rotating roll orother means suitable for generating a perforation. Preferably theperforation of the film takes place by means of a rotating roll withattached needles. Alternatively, the perforation may also be generatedby slit and hole punches. The perforation permits ambient air trapped inthe film tube as well as reaction gases evolved during the foamingreaction of the free-flowing reaction mixture to escape and thusprevents gas inclusions, which may cause bubble formation inside theprofile element or under the film. Because of the perforation and thusthe ability of the gas to escape, uniform shaping is assured.

In a subsequent step of the inventive method, the film is laid flat on aconveying means, preferably a conveyor belt or treadmill, and passedover a forming shoulder, where the side-edge regions of the film areturned up slightly in order that the free-flowing reaction mixture canbe applied in a subsequent step.

According to the invention, a deformable free-flowing reaction mixtureis used in the method. This material may be either plastically orelastically deformable. Preferably the deformable free-flowing reactionmixture is a polyethylene, a polyurethane or a cellular-rubber mixture.In particular, the profile element in finished condition consists of amaterial that is resilient after compression, such as foam, spongerubber, cellular rubber or the like. Common foams such as polyethyleneand polyurethane foams or cellular rubber can be mentioned as foammaterial. This foam may be an open-celled foam with very low air passageresistance, or else an approximately closed-celled foam with extremelylow air permeability values. Even foams with air permeability valueslying between the two extreme cases mentioned in the foregoing may beused within the scope of the present invention. Preferably, thefree-flowing reaction mixture is a polyurethane mixture.

It has proved advantageous when the profile element manufacturedaccording to the inventive method consists of a slow-burning foam, sucha cellular rubber or polyurethane foam, for example, which is jacketedwith a film. In the case of a slow-burning foam, there is no possibilitythat fire will be propagated by the foam. Spontaneous inflammation isruled out by the above-mentioned foam-type starting materials. It isalso advantageous that no dripping occurs in the event of fire. Aslow-burning foam should still have at least 20%, still at least 25%,preferably still at least 30%, between 20% and 60%, between 20% and 40%,preferably between 25% and 30% of its initial volume in a temperaturerange between 500° C., and 800° C. Furthermore, a slow-burning foamshould still have at least 10%, at least 20%, preferably still at least30%, between 10% and 40%, between 10% and 30%, preferably between 15%and 20% of its initial mass in a temperature range between 500° C., and800° C.

Furthermore, the deformable free-flowing reaction mixture may containappropriate additives if fire protection properties such asintumescence, for example, are desired. Under the effect of heat, suchas in the event of fire, the material swells and forms an insulatinglayer of flame-retardant material. The formation of a voluminousinsulating layer, namely an ash layer, may take place due to thechemical reaction of a mixture of compounds that are appropriatelymatched to one another and that react with one another under the effectof heat. Such systems are known to the person skilled in the art aschemical intumescence, and they may be used according to the invention.Alternatively, the voluminous insulating layer may be formed by swellingof an individual compound, which releases gases under the effect ofheat, even though no chemical reaction has occurred between twocompounds. Such systems are known to the person skilled in the art asphysical intumescence, and they may also be used according to theinvention. According to the invention, the two systems may be usedrespectively alone or together as a combination.

In a preferred embodiment of the method of the present invention, thefree-flowing reaction mixture is an intumescent polyurethane mixture.

As an example, the free-flowing reaction mixture may be mixed in anupstream mixing process, e.g. already in a system suitable forapplication of the free-flowing reaction mixture, such as a castingsystem.

According to the invention, the application of the free-flowing reactionmixture takes place by uniform orthogonal dosing on an upper side of thefilm. In particular, it is necessary, for inventive manufacture of theprofile element, that the free-flowing reaction mixture be dosed inuniformly orthogonal manner on the upper side of the open, flat film.Thereby the backing-up of the material compound that may occur in analready prefabricated tube during the manufacturing process, orinsufficient material compound in the manufactured joint cord, isprevented. Preferably, the volume of the free-flowing reaction mixtureto be applied is dosed such that in the fully reacted state itcorresponds to the inside volume of the manufactured profile element.

The filled film is then passed by means of conveying equipment to awelding system, where a first side-edge region of the film is joinedwith a second side-edge region of the film to create a substantiallycylindrical profile element. Preferably, the step of joining by thermalwelding takes place with formation of a fish-fin weld seam. In theprocess, the film should completely enclose the reaction mixture.

The tubular profile element formed in this way is then passed by meansof conveying equipment over a reaction section, in which foaming of thefree-flowing reaction mixture takes place. Preferably, the foaming ofthe free-flowing reaction mixture takes place within a time interval of15 to 90 seconds. The foaming takes place between the thermal weldingsystem and a cutting unit. In a particular embodiment of the method ofthe present invention, the conveying equipment comprises a conveyor beltor treadmill with guide elements, e.g. knobs or dimples, for exactlyguiding the film.

During passage over the reaction section, shaping to the desired profilegeometry may optionally take place. Preferably, the desired profilegeometry can be formed by at least one metal profile. Thereupon thefinished profile element is passed to a cutting unit, where cutting ofthe profile element to the desired length takes place.

In this way the inventive method permits cost-effective, economic,continuous and endless manufacture of profile elements. The inventivemethod is preferably carried out by means of an apparatus formanufacturing such profile elements.

Such an apparatus for manufacturing such profile elements is providedwith a casting system for mixing and applying a free-flowing reactionmixture and is characterized by

a) a feed apparatus for feeding a film,

b) a roll for perforating the film,

c) at least one conveying means for laying the film flat and conveyingit,

d) a forming shoulder for shaping the profile element,

e) a thermal welding system for joining a first side-edge region of thefilm with a second side-edge region of the film,

f) a reaction section for foaming the free-flowing reaction mixture,

g) conveying equipment for exactly guiding the film,

h) a cutting unit for cutting the profile element to the desired length,and

i) optionally at least one metal profile for shaping the profile to thedesired geometry.

Preferably, the feed apparatus for feeding the film comprises at leastone roll. Further preferably, the conveying equipment for exactlyguiding the film comprises a conveyor belt or treadmill with guideelements, e.g. knobs or dimples. Preferably, the metal profile forshaping the desired profile geometry may be provided with any desiredshape, and thus the profile geometry of the profile element can bepredetermined.

Particular practical importance is attached to one special configurationof the profile element manufactured according to the invention forsealing a joint between a first building part and a second buildingpart, wherein the profile element comprises an elongated connectingelement and at least two sealing regions, which are positioned on theconnecting element, along the outer periphery, spaced apart,side-by-side and running in the longitudinal direction of the connectingelement. Preferably, the profile element manufactured according to theinvention is used for acoustic, smokeproof and/or fireproof sealing ofconnecting joints in drywalls. In this connection, it is particularlypreferred that the profile element be positioned in the upper region ofthe connecting joint and be configured to seal the joint from theoutside.

Preferred cross-section shapes of the sealing regions of the profileelement manufactured according to the invention are round profile andpolygonal profile, especially rectangular profile, square profile,parallelogram profile and triangular profile. Round profile isparticularly preferred. Nevertheless, other or mixed profile geometriesare also conceivable and possible, as long as the sealing regions adjoinboth building parts after installation of the profile element and areable to seal the joint that is present between the building parts.

The dimension and profile geometry as well as the materials of theprofile element manufactured according to the invention are chosen tocorrespond to the planned use of the profile element.

In general, the dimension of the profile element manufactured accordingto the invention is chosen as a function of the profiles being used andof the material being used. The dimension must be chosen such that theprofile element fills the gap between the gypsum board and the ceilingand bears sealingly both on the ceiling and on the gypsum board. If avertical movement of the gypsum boards is to be permitted, the profileelement, especially the sealing regions, must follow the movement of thegypsum board, so that the contact with the gypsum board is not tornapart and no spaces are able to form between sealing region and gypsumboard. For this purpose, the profile element manufactured according tothe invention consists of resilient and compressible material, such aspolyurethane foam, and is appropriately precompressed during mounting ofthe gypsum board, so that a downward movement of the gypsum board,whereby the gap between this and the ceiling becomes larger, can befollowed. In this way, the preadjusted freedom of movement of the gypsumboard determines the dimension of the profile element.

The region of the connecting element disposed between the two sealingregions defines a support region, which consists only of the connectingelement. This support region is dimensioned such that it corresponds atleast to the width of the web of the channel profile. Hereby theinstallation and especially the positioning of the profile element onthe web of the channel profile are facilitated.

The positioning of the profile element on a building part may beachieved in one step. It is also possible that the profile element inturn has means for fastening to a building part, such as a drywallprofile, for example in the form of a self-adhesive layer, in the formof interlocking or frictionally acting means, such as suitable profiledshapes or the like. The profile element manufactured according to theinvention is preferably positioned on a building part in one step.

The use of a profile element manufactured according to the inventioncomprises, before attachment of a first building part, positioning onthe first building part, and then fastening together therewith on asecond building part in the usual way, e.g. by screws or nails.Preferably the first building part is a frame profile of a drywallstudwork, for example a channel profile, and the second building part isa wall, a ceiling or a floor of a building structure. Particularlypreferably, the first building part is a channel profile and the secondbuilding part is a ceiling. In this arrangement, the profile element ispositioned in the outer region of the joint, especially of theconnecting joint, and is configured to seal the joint from the outside.

When the profile element manufactured according to the invention is usedon the channel profile and abutted with the ceiling, irregularities inboth building parts can be evened out and simple positioning withoutadhesive bonding is possible. Furthermore, the joint spacing can becontrolled by the subsequent positioning of the gypsum board as well asby the choice of sealing material and/or geometric configuration of theprofile element.

The profile element manufactured according to the invention can beapplied on all kinds of connecting joints in which one building partmeets another building part. Accordingly, the profile element may beused on all profiles, even closed profiles or wooden beams, which mustbe sealed to a connecting face.

A particularly preferred use of the profile element manufacturedaccording to the invention therefore relates to the sealing of profilesin dry construction, wherein the first building part is a floor, aceiling or a wall of a building element, for example a masonry structureor concrete building element, and the second building part is a ceiling,floor or wall profile or a metal or wood studwork of a dry constructionelement. The profile may be any of the profiles commonly used for dryconstruction, regardless of whether it has a slotted or non-slotted webor slotted or non-slotted flange. The further building parts are gypsumboards, which bear closely on the profiles and are fastened to thestudwork. In order to permit vertical movement of the gypsum boards, forexample in the event of an earthquake, the gypsum boards are mounted tobe vertically movable at a spacing from a wall, a floor or a ceiling.Thereby a space (also referred to as joint herein) is formed between thegypsum board and the wall, the floor or the ceiling. This joint isfilled by the profile element, so that the profile element seals thejoint against sound and/or smoke and, depending on material of thesealing strip, also optionally against fire.

Without restricting the scope of protection of the invention, theinvention will be described in more detail on the basis of themanufacture of an inventive profile element by means of an apparatus,which is schematically illustrated in FIG. 1.

In the apparatus, illustrated in FIG. 1, for manufacturing a profileelement 1, a polyethylene film is passed from a film stock 3 by means ofa feed apparatus over at least one roll 4, where perforation takesplace. The perforation is performed by a rotating roll 4 with attachedneedles. The film is then laid flat on a conveying means 5 and passedover a forming shoulder 6, where the side-edge regions of the film areturned up in order that a free-flowing intumescent polyurethane materialcan be applied. The free-flowing polyurethane material is mixed by meansof a casting system 2 and applied to the film by uniform orthogonaldosing on the upper side of the film. The film is then passed by meansof conveying means 5 to a thermal welding system 7, where a firstside-edge region of the film is joined with a second side-edge region ofthe film by thermal welding to produce a fish-fin weld seam. Thereafterthe tubular profile element formed in this way is passed by means ofconveying equipment 9 over a reaction section 8, in which foaming of thepolyurethane mixture takes place. The desired profile geometry is shapedby at least one metal profile 11. Thereupon the finished profile element1 is passed to a cutting unit 10, where cutting of profile element 1 tothe desired length takes place.

FIGS. 2a to 2c show a preferred embodiment of a profile element 1manufactured according to the invention. Profile element 1 has twosealing regions 1 a and 1 b, which are positioned on the outerperipheries of connecting element 1 c. Sealing regions 1 a and 1 b havea round profile and a solid profile, and connecting element 1 c has asolid profile. Sealing regions 1 a and 1 b and connecting element 1 cconsist of a compressible polyurethane foam (1 e), which optionallycontains fire-protection additives. Polyethylene film 1 d completelyencloses the polyurethane foam.

FIG. 3 sketches the application of the embodiment of a profile element,illustrated in FIGS. 2a to 2b and manufactured according to theinvention, for acoustic, smokeproof and/or fireproof sealing ofconnecting joints in drywalls. To seal the gap between a ceiling 12,channel profile 13 of a drywall studwork and gypsum boards 14, in thefirst step, profile element 1 is laid on the web of channel profile 13and, in the second step, is fastened together therewith on ceiling 12 inthe usual way, e.g. by screws or nails. Then, in a last step, gypsumboards 14 are applied on the flanges of channel profile 13 and pushedupward in the direction of ceiling 12, whereupon a gap remains betweenthe top edge of gypsum board 14 and ceiling 12, which is filled withsealing regions 1 a and 1 b of profile element 1, in order to permitvertical movement, for example, of gypsum board 14. Thereby sealingregions 1 a and 1 b are pressed together and thus seal the gap betweenceiling 12 and channel profile 13 and the gap between ceiling 12 andgypsum board 14. Thus profile element 1 is positioned in the upperregion of the connecting joint and is configured to seal the joint fromthe outside.

As is obvious from the foregoing explanations, the inventive method issuitable in particular for manufacturing, in cost-effective, economic,continuous and endless manner, a profile element for acoustic,smokeproof and/or fireproof sealing of connecting joints in drywalls,especially of expansion joints.

The inventive method and the inventive apparatus are characterized inparticular by the following advantages compared with prior art systems:

Because of the uniform orthogonal dosing on the surface of the film, nocontamination of possible process supply lines occurs, since the foamcomes into contact only with the film and not with further apparatuscomponents. Furthermore, the apparatus permits quick setup for otherdimensions and diameters of the desired profile element, e.g. byexchanging the forming shoulders and adjusting the film width as well asthe desired length of the profile element, without laborious setup. Theinventive method and the apparatus permit the manufacture of profileelements with a diameter of approx. 25 mm to approx. 70 mm and a lengthof up to 5 m.

Due to the flexible use of several metal profiles, the profile geometrycan be freely configured, depending on the desired service area. Thefilm of the profile element manufactured according to the inventionsimultaneously functions as a mounting aid, i.e. further mountingaccessories are not necessary, and it is not removed before use. Thisfurther has the advantage that the profile element can be mountedquickly and that the foam is protected from sprayed or splashed water aswell as during installation.

Furthermore, the inventive method and device prevent the backing-up ofthe material compound that may occur in an already prefabricated tubeduring the manufacturing process, or they prevent insufficient materialcompound in the manufactured joint cord. Furthermore, the intermixingquality/homogeneity of the foam is not influenced by the shaping step.

As is also obvious from the foregoing explanations, the profile elementmanufactured according to the invention is particularly suitable forsafely sealing a building-structure joint between two adjacent buildingparts in simple manner, especially against sound and/or smoke andoptionally also against fire.

Furthermore, application is very mounting-friendly, since no additionalfastening of the profile element, for example to the profile or to theceiling, is necessary. Accurately fitting application of the profileelement, for example against a profile, is likewise unnecessary, byvirtue of the self-centering of the profile element during mounting ofthe profile on a building part. Mounting is therefore conceivably easy,and the working effort for mounting the profile element is greatlyreduced. The profile element manufactured according to the inventiontherefore achieves safe and reliable sealing of joints between twobuilding parts, especially between a profile of a dry-constructionstudwork and a building part adjacent thereto, such as, for example, aceiling, wall or floor. In this connection, two-sided sealing can beachieved in only one operation, by providing a prefabricated profileelement.

Furthermore, it has been shown that outstanding imperviousness can beachieved with the profile element manufactured according to theinvention, since good compressibility of the sealing regions is ensuredwithout additional auxiliary means by the choice of the sealingmaterials and/or geometric configuration. The profile elementsmanufactured according to the invention also make it possible to adjustthe correct spacing of gypsum board from the connecting building partwithout additional auxiliary means, in order to achieve the saidprecompression.

By means of the profile element manufactured according to the invention,it is also possible to ensure that, merely by the choice of the sealingmaterials and/or geometric configuration, sufficient material isinstalled to ensure excellent imperviousness with maximum absorption ofmovement.

Furthermore, with the profile element manufactured according to theinvention, irregularities of the surface of a building part can bereliably sealed as soon as one building part is disposed on anotherbuilding part, since the sealing elements of the joint-sealing tape arepressed sufficiently firmly against the surface of the one building partand at the same time against the side faces of the other building part.

In view of the foregoing, it is obvious that the objects of theinvention have been solved. Since various modifications can be made tothe method described in the foregoing, to the apparatus, to the profileelement manufactured according to the invention and to the use thereofwithout departing from the scope of the invention, it is intended thatall subject matters contained in the foregoing description beinterpreted as illustrative and not in a restrictive sense.

1-13. (canceled) 14: A profile element, manufactured by a method comprising: a) providing a film, b) applying a free-flowing reaction mixture on an upper side of the film, c) joining a first side-edge region of the film with a second side-edge region of the film to create a profile element of a first shape, d) foaming the free-flowing reaction mixture, and e) shaping the profile element to a second shape different from the first shape by applying pressure to the film using at least one profile corresponding to the second shape, wherein foaming the free-flowing reaction mixture of d) is performed during a first period and shaping the profile element of e) is performed during a second period at least partially overlapping the first period, wherein a volume of the free-flowing reaction mixture to be applied is dosed such that, in a fully reacted state, the volume corresponds to an inside volume of the profile element with the film completely enclosing the free-flowing reaction mixture, and wherein the at least one profile applies the pressure during the first period of time while the free-flowing reaction mixture is being foamed, to thereby simultaneously foam the free-flowing reaction mixture and shape the profile element with the at least one profile for a duration of overlap between the first and second periods, the pressure applied by the at least one profile to form at least a first region and a second region of the profile element, the first and second regions having respective first and second shapes and joined to have a continuous one-piece construction formed from the free-flowing reaction mixture. 15-16. (canceled) 17: The profile element according to claim 14, wherein the profile element is cut to a desired length. 18: The profile element according to claim 14, wherein said b) applying comprises uniform orthogonal dosing of the free-flowing reaction mixture on an upper side of the film. 19: The profile element according to claim 14, wherein said joining c) comprises joining the first side-edge region with the second side-edge region of the film by thermal welding. 20: The profile element according to claim 14, wherein the film comprises polyethylene and is perforated. 21: The profile element according to claim 14, wherein the free-flowing reaction mixture is a polyurethane mixture. 22: The profile element according to claim 21, wherein the polyurethane mixture is an intumescent polyurethane mixture. 23: The profile element according to claim 14, further comprising: a third region between the first region and the second region, wherein the third region has a third shape different from the first shape or the second shape. 24: The profile element according to claim 14, wherein the foaming d) takes place within a time interval of 15 to 90 seconds. 25: The profile element according to claim 14, wherein the method is a continuous and endless method. 26: A method of sealing a connecting joint in drywall, comprising: attaching the profile element according to claim 14 to a connecting joint in drywall, wherein the sealing is at least one member selected from the group consisting of an acoustic sealing, a smokeproof sealing, and a fireproof sealing. 27: The method according to claim 26, wherein, upon the attaching, the profile element is attached to an upper region of the connecting joint and is configured to seal the connecting joint from an outside of the connecting joint. 28: A method of making a profile element, comprising: forming the profile element with an apparatus comprising: a) a feed apparatus for feeding a film, b) a roll for perforating the film, c) at least one conveyor for laying the film flat and conveying the film, d) a forming shoulder to apply pressure to the film for shaping the profile element, e) a thermal welding system for joining a first side-edge region of the film with a second side-edge region of the film to form the profile element of a first shape, f) a reaction section for foaming a free-flowing reaction mixture, g) at least one shaping profile to shape the profile element to a second shape different from the first shape, and h) a cutting unit for cutting the profile element to a desired length, wherein the reaction section is to foam the free-flowing reaction mixture during a first period and the at least one shaping profile is to shape the profile element during a second period at least partially overlapping the first period, wherein the at least one shaping profile has a shape which simultaneously applies pressure to the film of the profile element during the first period of time while the free-flowing reaction mixture is being foamed, to thereby simultaneously foam the free-flowing reaction mixture and shape the profile element with the at least one shaping profile for a duration of overlap between the first and second periods, the pressure applied by the at least one shaping profile to form at least a first region and a second region of the profile element, the first and second regions having respective first and second shapes and joined to have a continuous one-piece construction formed from the free-flowing reaction mixture. 29: The profile element produced by the method according to claim
 28. 30: The profile element according to claim 20, wherein the film is perforated before foaming the free-flowing reaction mixture, and wherein the film comprises polyethylene. 31: The profile element according to claim 14, wherein the at least one profile applies pressure to the film to simultaneously form a third region between the first and second regions, and the third region has a third shape different from the first shape and the second shape and is joined to have a continuous one-piece construction with the first and second regions. 32: The profile element according to claim 31, wherein the first shape is same as the second shape. 33: The profile element according to claim 31, wherein the first region is spaced from the second region by a predetermined distance, which corresponds to a distance between a first building feature and a second building feature to be sealed by the profile element. 34: The profile element according to claim 33, wherein the first building feature is a ceiling, and the second building feature is a gypsum board or a feature of the gypsum board. 35: A profile element, comprising: a film, wherein a first side-edge region of the film is joined with a second side-edge region of the film, and a foamed reaction mixture, wherein a volume of the foamed reaction mixture corresponds to an inside volume of the profile element, with the film completely enclosing the foamed reaction mixture, wherein the profile element comprises a first region and a second region, respectively having a first shape and a second shape, and wherein the first region and the second region are joined to have a continuous one-piece construction formed from the foamed reaction mixture. 